Carton with Three Dimensional Handle

ABSTRACT

A carton includes a tray ( 110 ) and a lid ( 120 ). The tray includes a pair of handles ( 400, 405 ), each comprising a first panel ( 370 ) extending in a first direction, a second panel ( 350 ) extending in a second direction, and a third panel ( 330 ) extending in a third direction. The lid is removably attached to the tray. The lid is positioned between the pair of handles.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Application No. 60/683,220, filed May 19, 2005, the entirety of which is incorporated herein by reference.

TECHNICAL FIELD

The present invention relates generally to a carton for articles and more particularly relates to a carton with one or more reinforced, three-dimensional handles.

BACKGROUND OF THE INVENTION

Cartons for articles such as beverage containers and the like generally may be made out of cardboard, paperboard, corrugated board, or similar types of materials. The material generally is cut, folded, and then glued into the appropriate shape. The design of the carton thus may focus on minimizing the amount of material and adhesives used while maximizing the strength of the carton as a whole. Likewise, the carton preferably should be easy to assemble, load, carry, and unload.

SUMMARY OF THE INVENTION

A carton thus may be described herein. The carton may include a pair of opposed walls with a first dimension. At least one of the walls may include a tubular handle. The tubular handle may extend across the first dimension of the wall.

The pair of opposed walls may include a handle cutout positioned therein adjacent to the tubular handle. The carton further may include a pair of the tubular handles. The tubular handles may include a reinforcing member.

The tubular handle may include a first panel extending in a first direction, a second panel extending in a second direction, and a third panel extending in a third direction. The first direction may include a substantially horizontal direction. The second direction may include a substantially vertical direction or a substantially diagonal direction. The third direction may include a substantially horizontal direction or a substantially vertical direction.

The carton further may include a fourth panel extending in a fourth direction. The fourth direction may include a substantially vertical direction or a substantially horizontal direction.

A further embodiment of the carton may include a tray with a pair of handles. The pair of handles each may include a first panel extending in a first direction, a second panel extending in a second direction, and a third panel extending in a third direction. A lid may be removably attached to the tray. The lid may be positioned between the pair of handles.

The tray may include a first end panel and a second end panel such that each panel has one of the handles and a handle cutout positioned therein. The handles may be fixedly attached to the tray via adhesives. The lid may include a zipper or a pair of zippers formed therein. The handles may include a reinforcing member.

The first direction may include a substantially horizontal direction. The second direction may include a substantially vertical direction or a substantially diagonal direction. The third direction may include a substantially horizontal direction or a substantially vertical direction. The carton further may include a fourth panel extending in a fourth direction. The fourth direction may include a substantially vertical direction or a substantially horizontal direction.

A further embodiment of the carton may include a tray with a pair of handles. The handles each may include a first panel extending in a first horizontal direction, a second panel extending in a first vertical direction, a third panel extending in a second horizontal direction, and a fourth panel extending in a second vertical direction. A lid may be removably attached to the tray. The handles may be positioned laterally of the lid. The tray may include a pair of handle cutouts positioned adjacent to the pair of handles. Each of the handles may be fixedly attached to the tray via adhesives. The lid may include a pair of zippers formed therein. The handles may include a reinforcing member.

A further embodiment of the carton may include a tray with a pair of tubular handles. The tubular handles each may include a first panel extending in a first horizontal direction, a second panel extending in a diagonal direction, and a third panel extending in a vertical direction. A lid may be removably attached to the tray. The tubular handles may be positioned laterally of the lid. The carton further may include a fourth panel extending in a second horizontal direction. The tubular handles may include a reinforcing member.

These and other features of the present invention will become apparent upon review of the following detailed description when taken in conjunction with the drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a blank used to assemble the tray of the carton as described herein.

FIG. 2 is a perspective view of a handle as described herein.

FIG. 3 is a perspective view of a modified form of the handle in FIG. 2.

FIG. 4 is a perspective view of another modified form of the handle in FIG. 2.

FIG. 5 is a plan view of a blank used to assemble the lid as described herein.

FIG. 6 is a perspective view of an assembled carton.

FIG. 7 is a perspective view of a further modified form of the handle in FIG. 2, having a core member as described herein.

FIG. 8 is perspective view of a further modified form of the handle in FIG. 2, having a sloping panel that extends directly from the upper edge of the associated end panel of the carton.

FIG. 9 is a perspective view of a further modified form of the handle in FIG. 2, having a backing panel formed with an alignment aperture.

DETAILED DESCRIPTION

Referring now to the drawings, in which like numerals refer to like elements throughout the several views, FIGS. 1-7 show embodiments of a carton 100 as described herein. The carton 100 may be a two (2) piece container with a first part 110 and a second part 120. The first part 110 may be a tray or a similar type of open basket structure and the second part 120 may a lid or a similar type of covering structure and/or support structure. A one piece carton or a carton with more than three (3) elements also may be used herein.

The first part 110 and the second part 120 may be made out of cardboard, paperboard, corrugated board, plastic, or similar types of foldable sheet materials. Specifically, the first part 110 and the second part 120 may be made out of coated unbleached paperboard. The thickness of the material for the first part 110 and the second part 120 may be varied.

FIG. 1 shows a blank that may be used to assemble the first part 110, the tray. The blank may be cut in a die cutting process, a laser cutting process, or any other type of cutting method from a continuous or precut sheet of foldable material.

The blank may have a number of fold lines and tear lines formed therein. The term fold line refers to a weakened line that facilitates folding of the material along the length of the weakened line. The fold line is not limited to one kind of constituent line but includes a score line, a perforation, a line of short slits, a line of half cuts, a combination of slits and score lines, and similar arrangements. Any reference to a fold line or any hinged connection should not be construed as being limited to a single constituent line only. Any such fold line or hinged connection may be formed from one or more constituent lines. The term tear line may refer to a line of severance or any other weakened line that facilitates separation along the length of the weakened line. The tear line may include, but is not limited to, a perforation, a line of short slits, a line of half cuts, a combination of slits and score lines, and similar arrangements. Any reference to a tear line or any weakened line should not be construed as being limited to a single constituent line only. Any such tear line or weakened line may be formed from one or more constituent lines.

The fold lines may define a number of panels. Specifically, a base panel 160, a first side panel 161, a second side panel 162, a first end panel 170, and a second end panel 180 may be used. Additional panels also may be used as will be described below. The number of panels may be varied. Each of the panels may be largely rectangular in shape. Any desired size or shape, however, may be used. It will be recognized that ordering references, such as first and second, and directional references, such as top, base, bottom, side, upper, lower, etc., do not limit the structure described herein to such orientation, but merely serve to distinguish relative structure from one another.

The base panel 160 may have a number of beveled edges 165 such that the base panel 160 as a whole may have a largely octagonal shape. The beveled edges 165 may accommodate the size and shape of the beverage containers, such as bottles, and provide a stable carton 100 as a whole when loaded.

The side panels 161, 162 may be largely identical in shape. The first side panel 161 may be connected to the base panel 160 via a first side panel fold line 163. Likewise, the second side panel 162 may be connected to the base panel 160 via a second side panel fold line 164.

The end panels 170, 180 may be largely identical in shape. The first end panel 170 may be connected to the base panel 160 via a first base panel fold line 190. The first end panel 170 may have a handle cutout 200 positioned therein. The handle cutout 200 may have an extended oval shape. The handle cutout 200 may be defined at least in part by a handle flap 220. The handle flap 220 may be folded onto the first end panel 170 for reinforcement as well as to form a hand cushion.

The first end panel 170 also may be connected to a pair of corner panels. Specifically, a first corner panel 230 and a second corner panel 240. In this example, the corner panels 230, 240 may have a largely trapezoidal shape, with one corner at a right angle and another corner at about an obtuse angle (e.g., a 135-degree angle). Any size or shape, however, may be used. The first corner panel 230 may be connected to the first end panel 170 by a first corner panel fold line 250. Likewise, the second corner panel 240 may be connected to the first end panel 170 by a second corner panel fold line 260.

The corner panels 230, 240, in turn, also may be connected to a pair of reinforcing panels. Specifically, a first reinforcing panel 270 and a second reinforcing panel 280. In this example, the reinforcing panels 270, 280 also may have a largely trapezoidal shape. Any size or shape, however, may be used. The first reinforcing panel 270 may be connected to the first corner panel 230 by a first reinforcing panel fold line 290. Likewise, the second reinforcing panel 280 may be connected to the second corner panel 240 by a second corner panel fold line 295. Additional fold lines and panels also may be used.

The first end panel 170 also may be connected to a first handle panel arrangement 300. The overall handle panel arrangement 300 may be largely rectangular in shape. The handle panel arrangement 300 may connect to the first end panel 170 by a first handle panel fold line 310.

The handle panel arrangement 300 may have a first horizontal panel 320 connected to the first end panel 170 via the first handle panel fold line 310. In turn, the first horizontal panel 320 may be connected to a first vertical panel 330. A second handle panel fold line 340 may connect the first horizontal panel 320 and the first vertical panel 330. Likewise, the first vertical panel 330 may be connected to a second horizontal panel 350. A third handle panel fold line 360 may connect the first vertical panel 330 and the second horizontal panel 350. Further, the second horizontal panel 350 may be connected to a second vertical panel 370. A fourth handle panel fold line 380 may connect the second horizontal panel 350 and the second vertical panel 370. The second horizontal panel 350 and the second vertical panel 370 may be slightly tapered inward along the lateral edges, or along the short dimension.

The first horizontal panel 320 and the second horizontal panel 350 may have about the same length. Likewise, the first vertical panel 330 and the second vertical panel 370 may have about the same length. As will be described in more detail below, any number of panels or fold lines, in any orientation, may be used. Other angles, shapes, and sizes also may be used herein.

The combination of these panels 320, 330, 350, 370 thus forms a handle 400. A perspective view of the handle 400 is shown in FIG. 2. As is seen, the handle 400 is of a largely three-dimensional, tubular form having a rectangular cross section. The handle 400 runs about the entire length of the first end panel 170.

The second end panel 180 of the first part 110 or the tray may be connected to the base panel 160 by a second base panel fold line 410. As above, the second end panel 180 may be largely identical to the first end panel 170 and the same signals are incorporated herein. Specifically, the second end panel 180 may have a second handle 405 formed therein similar to the handle 400 described above.

FIG. 3 shows a modified form 450 of the handle 400 or 405 that may be used in place of either or each of the handles 400 and 405. The modified handle 450 may include the first horizontal panel 320 connected to the respective end panel 170 or 180 by the first handle panel fold line 310. Instead of the first vertical panel 330, the handle 450 may have a first diagonal panel 460. The first diagonal panel 460 may extend at an acute angle (e.g., about a forty-five degree angle) from the horizontal. The first diagonal panel 460 may extend towards the respective end panel 170 or 180. A second handle panel fold line 470 may connect the first horizontal panel 320 and the first diagonal panel 460.

The first diagonal panel 460 may lead to a first vertical panel 480. A third handle panel fold line 490 may connect the first vertical panel 480 and the first diagonal panel 460. The first vertical panel 480 may be attached to the respective end panel 170 or 180 by adhesives or other types of joinder means. Other angles, shapes, and sizes may be used herein.

FIG. 4 shows a further modified form 500 of the handle 400 or 405 that may be used in place of either or each of the handles 400 and 405. The second modified handle 500 may be largely identical to the modified handle 450 but with the addition of a second horizontal panel 510. A fourth handle panel line 520 may connect the second horizontal panel 510 and the first vertical panel 480. The second horizontal panel 510 may, or may not, be attached to the first horizontal panel 320 by adhesives or other types of fixture means. Other angles, shapes, and sizes may be used herein. Other variations on the handles also may be used herein so as to provide the three-dimensional feel and grasp.

FIG. 5 shows a blank for the second part 120 or the lid. As above, the blank may have a number of fold lines and tear lines formed therein. The fold lines may define a number of panels. In this example, a top panel 610, a first side panel 620, a second side panel 630, a first end panel 640, and a second end panel 650 may be used. The number of panels may be varied. Each of the panels may be largely rectangular in shape. Any desired size or shape, however, may be used.

The first side panel 620 may be connected to the top panel 610 by a first base panel fold line 660. The first side panel 620 also may have a zipper 670 formed therein. By the term “zipper”, we mean that two or more tear lines are positioned such that a part of the first side panel 620 may be completely removed so as to bisect the first side panel 620. Each tear line that constitutes the zipper 670 may be in the form of a series of slits in any desired form or shape.

The second side panel 630 may be connected to the top panel 610 by a second base panel fold line 680. The second side panel 630, when folded, may be largely parallel to the first side panel 620. The second side panel 630 may be largely identical to the first side panel 620 in shape. The second side panel 630 also may include a zipper 670 positioned therein.

The first and second end panels 640, 650 may be largely identical to each other. When folded, the first and second end panels 640, 650 may be largely parallel to each other and perpendicular to the first and second side panels 620, 630. The first end panel 640 may be connected to the top panel 610 via a third base panel fold line 690 while the second end panel 650 may be connected to the top panel 610 by a fourth base panel fold line 700. The first and second end panels 640, 650 each may have a further fold line 710 therein so as to accommodate the overall shape of the first part 110 as well as the size and shape of the beverage containers, such as bottles, packaged in the carton 100.

To form the first part 110 or the tray, the side panels 161, 162 may be folded about the side panel fold lines 163, 164. Likewise, the end panels 170, 180 may be folded about the panel fold lines 190, 410. The corner panels 230, 240 and the reinforcing panels 270, 280 may be attached to the side panels 161, 162 by adhesives or other types of joinder means.

The handle panel arrangement 300 may be constructed in any order. For example, the second vertical panel 370 may be folded about the fourth handle panel fold line 380, the second horizontal panel 350 may be folded about the third handle panel fold line 360, the first vertical panel 330 may be folded about the second panel fold line 340, and the first horizontal panel 320 may be folded about the first handle panel fold line 310. Once folded, the first horizontal panel 320 may be positioned at about a ninety-degree (90°) angle to the respective end panel 170 or 180. The first vertical panel 330 may be about at a ninety-degree (90°) angle from the first horizontal panel 320 and largely parallel to the respective end panel 170 or 180. The second horizontal panel 350 may be largely perpendicular to the first vertical panel 330 and largely parallel to the first horizontal panel 320. Finally, the second vertical panel 370 may be largely perpendicular to the second horizontal panel 350 and largely parallel to the first vertical panel 330 and the respective end panel 170 or 180. The second vertical panel 370 may be attached to the respective end panel 170 or 180 by adhesives or other types of joinder means. The use of adhesives may not be required for the handle 400. For example, a friction fit may be used.

Once constructed, the first part 110 then may be filled with one or more articles, in this case a number of beverage containers such as bottles. Any type of article, however, may be used. Alternatively, the first part 110 may be partially constructed before loading with the articles.

The second part 120 or the lid then may be attached to the first part 110 or the tray. Specifically, the first and the second side panels 620, 630 of the second part 120 may be attached to the side panels 161, 162 and the reinforcing panels 270, 280 of the first part 110. The side panels 620, 630 of the second part 120 preferably may be attached via adhesives applied below the zippers 670. Other joinder methods also may be used. Likewise, the end panels 640, 650 of the second part also may be positioned about, and preferably inwardly (FIG. 6) of, the handle of the first part 110. The handle may be grasped via the handle cutout 200. The first horizontal panel 320 may be unobstructed so as to position the user's thumb to assist in carrying the carton 100 as a whole.

The carton 100, with the beverage containers therein, may be carried via the handle or handles. As is described above, the handles have a three-dimensional shape that provides inherent or integral structure. The three-dimensional shape also provides rigidity to the handle and the carton 100 as a whole.

FIG. 6 shows the carton 100 with the second part 120 or the lid attached to the first part 110 or the tray. The second part 120 may be removed by pulling the zippers 670 on the first and second end panels 620, 630. A portion of the first and second end panels 620, 630 of the second part 120 below the zippers 670 may remain attached to the first part 110. The remaining portion of the first and second end panels 620, 630 provides sufficient structure to the first part 110 or the tray so as to maintain the beverage containers therein.

The beverage containers then may be removed from the first part 110 or the tray as desired. Likewise, the first part 110 or the tray also may be carried via the handle with the beverage containers generally remaining therein. Further, the first part 110 or the tray also may serve to return the empty beverage containers or other articles as is desired.

FIG. 7 shows a further modified form 750 of the handle 400 or 405 in FIG. 2. Although the outer tube portion of the modified handle 750 is shown as being identical to the handle 400, the outer tube portion of the handle 750 also may be in the form of the handle 450, the handle 500, or similar structures. In this embodiment, a reinforcing or core member 760 may be positioned within the outer tube portions of the handle 750. The core member 760 may take many different forms. The core member 760 may be in the form of a plastic or paper straw or tube, a folded or unfolded strip of paperboard or cardboard, a solid stick or bar of wood or plastic, or any type of three-dimensional element. The core member 760 may be positioned within the outer tube portion of handle 750 and provide additional strength thereto. The core member 760 may, or may not, be glued or otherwise attached to the outer tube portion of the handle 750.

FIG. 8 shows a modified form 800 of the handle 400 or 405 that may be used in place of either or each of the handles 400 and 405. The modified handle 800 may include a sloping panel 820, a base panel 840 and a backing panel 860. The sloping panel 820 is hingedly connected along a first fold line 810 to the upper edge of the respective end panel 870 that belong to the lower part of a carton of the invention. The sloping panel 820 extends downwardly and inwardly from the fold line 810. The sloping panel 820 defines an acute angle, preferably less than 45 degrees, with respect to the end panel 870.

The base panel 840 is hingedly connected to the lower edge of the sloping panel 820 along a second fold line 830 and extends toward the end panel 870. The base panel 840 defines an obtuse or acute angle, preferably no less than 45 degrees, with respect to the sloping panel 820. In the illustrated embodiment, the base panel 840 is disposed substantially horizontally. However, the base panel 840 may extend downwardly toward the end panel 870 to define an obtuse angle with respect to the sloping panel 820 so that the junction along the second fold line 830 provides more comfortable hand feeling when accessed by a user's hand.

The backing panel 860 is hingedly connected to the outer edge of the base panel 840 by a third fold line 850 and extends upwardly along the inside surface of the end panel 870. The backing panel 860 may be secured to the inside surface of the end panel 870 by known securing means such as adhesive, staples or any mechanical locking arrangement known in the packaging art. The backing panel 860 is placed on the upper portion of the end panel 870 between the upper edge 810 and the handle cutout 200 so that it does not interfere with the handle cutout 200 and yet reinforces the area of the end panel 870 immediately above the handle cutout 200.

FIG. 9 shows a modified form 900 of the handle 400 or 405 that may be used in place of either or each of the handles 400 and 405. The modified handle 900 may be associated with a carton end panel 970 that has an upper portion 970 a folded somewhat inwardly along an end panel fold line 980. The upper portion 970 a provides a sloping upper area along the upper edge 910 of the end panel 970. In one embodiment (not shown), the sloping upper portion 970 a may provide a sloping outside surface to which the end panel 640 or 650 of the associated upper part 120 may be secured.

The handle 900 may include a riser panel 920, a base panel 940 and a backing panel 960. The riser panel 920 is hingedly connected to the upper edge of the respective end panel 970 along a first fold line 910 and extends downwardly from the fold line 910. The riser panel 920 defines an acute angle, preferably less than 45 degrees, with respect to the sloping upper portion 970 a of the end panel 970 and may preferably be vertically disposed.

The base panel 940 is hingedly connected to the lower edge of the riser panel 920 along a second fold line 930 and extends substantially toward the end panel fold line 980. The base panel 940 defines an obtuse or acute angle, preferably no less than 45 degrees, with respect to the riser panel 920. In the illustrated embodiment, the base panel 940 is disposed substantially horizontally. However, the base panel 940 may extend downwardly toward the end panel 970, if not toward the fold line 980, to define an obtuse angle with respect to the riser panel 920.

The backing panel 960 is hingedly connected to the outer edge of the base panel 940 by a third fold line 950 and extends downwardly along that portion of the end panel 970 below the fold line 980. The backing panel 960 may be secured to the inside surface of the end panel 970. The backing panel 960 is formed with an alignment cutout 990 having a shape and size substantially identical to that of the handle cutout 200. The backing panel 960 is placed along the inside surface of the end panel 970 immediately below the fold line 980 such that the alignment cutout 990 is registered with the handle cutout 200 to cooperate therewith to provide a composite handle aperture. By this means, the backing panel 960 cooperates with the other part of the 3D handle 900 to effectively reinforce the area of the end panel 970 surrounding the handle cutout 200.

The above-described embodiments are merely exemplary illustrations of implementations set forth for a clear understanding of the principles of the invention. Variations, modifications, and combinations may be made to the above-described embodiments without departing from the scope of the claims. For example, as used herein, directional references such as “top”, “base”, “bottom”, “end”, “side”, “inner”, “outer”, “upper”, “middle”, “lower”, “front” and “rear” do not limit the respective walls of the carton to such orientation, but merely serve to distinguish these walls from one another. Although each embodiment is described with respect to a carton having a single dispensing aid deployed therein, it should be noted that a single carton may include several dispensing aids. For instance, two handle cutouts 200 may be replaced by a single handle cutout in only one of the end panels 170, 180. The 3D handle of the invention may be used with a carton formed from a single blank or with a tray-style carton with an open top. The 3D handle of the invention may be reinforced by an end panel of the first or upper part such as 640 or 650. Such reinforcement may be provided by gluing the end panel 650 to, for example, the vertical panel 330, diagonal panel 460, sloping panel 820 or riser panel 920 of the adjacent 3D handle or upper portion of the adjacent end panel of the carton.

All such variations, modifications, and combinations are included herein by the scope of this disclosure and the following claims. 

1. A carton, comprising: a pair of opposed walls; said pair of opposed walls comprises a first dimension; at least one of said pair of opposed walls comprises a tubular handle; and said tubular handle extending across said first dimension of said at least one of said pair of opposed walls.
 2. The carton of claim 1, wherein said tubular handle comprises a first panel extending in a first direction, a second panel extending in a second direction, and a third panel extending in a third direction.
 3. The carton of claim 2, further comprising a fourth panel extending in a fourth direction.
 4. The carton of claim 1, wherein said at least one of said pair of opposed walls comprises a handle cutout positioned therein below said tubular handle.
 5. The carton of claim 1, further comprising a reinforcing member positioned within said tubular handle
 6. The carton of claim 4, wherein said tubular handle comprises a backing panel disposed along an inside surface of said one opposed wall, said backing panel being located between an upper edge of said one opposed wall and said handle cutout so that the backing panel does not interfere with said handle cutout and yet reinforces an area of said one opposed end wall immediately above said handle cutout.
 7. The carton of claim 6, wherein said backing panel is secured to said inside surface of said one opposed wall.
 8. The carton of claim 6, wherein said backing panel is hingedly connected to said one opposed wall through at least two other panels.
 9. The carton of claim 8, wherein said other panels includes a first panel hingedly connected directly to an upper edge of said one opposed wall.
 10. The carton of claim 9, wherein said first panel is a sloping panel extending downwardly and inwardly from said upper edge of said one opposed wall, wherein said other panels further including a base panel hingedly connected to a lower edge of said sloping panel and extending toward said one opposed wall.
 11. The carton of claim 10, wherein said base panel defines an obtuse angle with respect to said sloping panel so that a junction between said sloping panel and said base panel provides comfortable hand feeling when accessed by a user's hand.
 12. The carton of claim 4, wherein said tubular handle comprises a backing panel having an alignment cutout defined therein, said backing panel being disposed along an inside surface of said one opposed wall such that said alignment cutout is registered with said handle cutout to cooperate therewith to provide a composite handle aperture.
 13. A carton, comprising: a tray; said tray comprising a pair of handles; each of said pair of handles comprising a first panel extending in a first direction, a second panel extending in a second direction, and a third panel extending in a third direction; and a lid removably attached to said tray; said lid positioned between said pair of handles.
 14. The carton of claim 13, wherein said tray comprises a first end panel and a second end panel and wherein first end panel and said second end panel each comprise one of said pair of handles.
 15. The carton of claim 14, wherein said first end panel and said second end panel each comprise a handle cutout positioned therein below a respective one of said pair of handles.
 16. The carton of claim 13, further comprising a fourth panel extending in a fourth direction.
 17. The carton of claim 13, wherein each of said pair of handles is fixedly attached to said tray via adhesives.
 18. The carton of claim 13, wherein said lid comprises a zipper formed therein.
 19. The carton of claim 13, wherein each of said pair of handles comprises a reinforcing member.
 20. The carton of claim 13, wherein each of said pair of handles extends substantially horizontally. 